Multi-filament yarns three-dimensional knitted fabric and system and method for manufacturing the same

ABSTRACT

A multi-filament three-dimensional knitted fabric and a system and a method for manufacturing the same are provided. The multi-filament three-dimensional knitted fabric includes a surface layer structure, a bottom layer structure and a support structure. The support structure is disposed between the surface layer structure and the bottom layer structure, the support structure includes a plurality of first multi-filament yarns, each of the first multi-filament yarns connecting to the surface layer structure and the bottom layer structure, and each of the first multi-filament yarns having a specific denier and being composed of a plurality of fibers.

FIELD OF THE DISCLOSURE

The present disclosure relates to a multi-filament three-dimensional knitted fabric and system and method for manufacturing the same, and more particularly to a multi-filament three-dimensional knitted fabric suitable for a variety of skin-friendly products, such as clothing, inner clothing, shoes, bags, hats, mattresses, medical supplies, and system and method for manufacturing the fabric.

BACKGROUND OF THE DISCLOSURE

With the vigorous development of fabric manufacturing, consumer demands for fabric quality are becoming more and more stringent, in addition to the appearance, delicate tactility is also required. Fabrics can be divided into fabrics made by weaving, knitting, plaiting, or braiding. The three-dimensional knitted fabric has the advantage of being soft and breathable, and is widely-used in various skin-friendly products, such as clothing, inner clothing, mattresses, and medical supplies. In the related art, monofilament fibers are commonly used as the support yarn. However, the commercially available monofilament fibers have poor support and stiffness, and the three-dimensional knitted fabrics produced by the conventional monofilament fibers can easily deform after molding, stitching or washing processes, so that the monofilament fibers puncture through the surface layer, to irritate the skin and cause discomfort.

In addition, in the related art, some disadvantages such as thickness losses of about 1.5 mm, and creasing or crushing of the product still exist in the three-dimensional knitted fabric manufacturing process.

Therefore, how the technical conflicts between support and skin-friendly technology can be solved, and how a skin-friendly tactility and comfort of three-dimensional knitted fabrics can be achieved by improvements in design, have become important topics in this field.

SUMMARY OF THE DISCLOSURE

In response to the above-referenced technical inadequacies, the present disclosure provides a multi-filament three-dimensional knitted fabric and system and method for manufacturing the same.

In one aspect, the present disclosure provides a multi-filament three-dimensional knitted fabric, including a surface layer structure, a bottom layer structure and a support structure. The support structure is disposed between the surface layer structure and the bottom layer structure, and the support structure includes a plurality of first multi-filament yarns, and each of the first multi-filament yarns is connected to the surface layer structure and the bottom layer structure, and interlacingly form the support structure.

In certain embodiments, each of the surface layer structure and the bottom layer structure includes a non-elastic fiber and an elastic fiber; wherein the ratio of the non-elastic fiber to the elastic fiber is between 70:30 and 97:3.

In certain embodiments, a thickness of the support structure is between 0.85 mm and 5 mm. In certain embodiments, a shrinkage of the multi-filament three-dimensional knitted fabric is between −5 and 0%.

In certain embodiments, a denier of the first multi-filament yarn is between 5 and 60 D, and the first multi-filament yarn is twisted from 2 to 75 yarns, and the denier of the yarn is between 0.5 to 30 D.

In certain embodiments, the yarn is at least one selected from the group consisting of nylon, polyester fiber, polylactic acid fiber, polytrimethylene terephthalate fiber, and cellulose fiber.

In another aspect, the present disclosure provides a system of manufacturing a multi-filament three-dimensional knitted fabric, including a weaving device including a yarn feeding unit, and the yarn feeding unit has a yarn feeder nozzle for interlacing and weaving at least one multifilament yarn into the multi-filament three-dimensional knitted fabric; in which, the multi-filament yarn passes through a yarn inlet of the yarn feeder nozzle at a yarn inlet angle between 40 and 55 degrees.

In yet another aspect, the present disclosure provides a method of manufacturing a multi-filament three-dimensional knitted fabric, including: weaving at least one multifilament yarn into a weaving device to form the multi-filament three-dimensional knitted fabric; in which, the multi-filament three-dimensional knitted fabric includes a surface layer structure, a bottom layer structure and a support structure. The support structure is disposed between the surface layer structure and the bottom layer structure, and the support structure includes a plurality of first multi-filament yarns, and each of the first multi-filament yarns is connected to the surface layer structure and the bottom layer structure, and interlacingly form the support structure. In which, the weaving device includes a yarn feeding unit, and the yarn feeding unit has a yarn feeder nozzle for interlacing and weaving at least one multifilament yarn into the multi-filament three-dimensional knitted fabric; wherein, the multi-filament yarn passes through a yarn inlet of the yarn feeder nozzle at a yarn inlet angle between 40 and 55 degrees.

Therefore, through the technical features of “the support structure includes a plurality of first multi-filament yarns” and “and each of the first multi-filament yarns is connected to the surface layer structure and the bottom layer structure, and interlacingly form the support structure, and interlacing the support structure”, the multi-filament three-dimensional knitted fabric of the present disclosure has a proper supporting force that is on par with that of fabric with monofilament fibers, as well as the effects of a better and more long-lasting elasticity property, and further provides better skin-friendly tactility and comfort, which overcomes the problems of itching and swelling of the skin from yarn puncturing out of the fabric surface.

In addition, the present disclosure further improves the manufacturing system and manufacturing method of the multi-filament three-dimensional knitted fabric, overcomes issues relating to thickness loss and defects of creases or crushing during a conventional manufacturing process, and further improves the efficiency and reduces the cost of the manufacturing process.

These and other aspects of the present disclosure will become apparent from the following description of the embodiment taken in conjunction with the following drawings and their captions, although variations and modifications therein may be affected without departing from the spirit and scope of the novel concepts of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from the following detailed description and accompanying drawings.

FIG. 1 is a schematic sectional view of a multi-filament three-dimensional knitted fabric according to a first embodiment of the present disclosure.

FIG. 2A is an enlarged schematic view of a multi-filament three-dimensional knitted fabric according to one embodiment of the present disclosure.

FIG. 2B is an enlarged schematic view of a multi-filament three-dimensional knitted fabric according to one embodiment of the present disclosure.

FIG. 3 is a schematic view of the structure of the yarn feeder nozzle of one embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present disclosure is more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. Like numbers in the drawings indicate like components throughout the views. As used in the description herein and throughout the claims that follow, unless the context clearly dictates otherwise, the meaning of “a”, “an”, and “the” includes plural reference, and the meaning of “in” includes “in” and “on”. Titles or subtitles can be used herein for the convenience of a reader, which shall have no influence on the scope of the present disclosure.

The terms used herein generally have their ordinary meanings in the art. In the case of conflict, the present document, including any definitions given herein, will prevail. The same thing can be expressed in more than one way. Alternative language and synonyms can be used for any term(s) discussed herein, and no special significance is to be placed upon whether a term is elaborated or discussed herein. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms is illustrative only, and in no way limits the scope and meaning of the present disclosure or of any exemplified term. Likewise, the present disclosure is not limited to various embodiments given herein. Numbering terms such as “first”, “second” or “third” can be used to describe various components, signals or the like, which are for distinguishing one component/signal from another one only, and are not intended to, nor should be construed to impose any substantive limitations on the components, signals or the like.

Referring to FIG. 1, an embodiment of the present disclosure provides a multi-filament three-dimensional knitted fabric F, including a surface layer structure 1, a bottom layer structure 2 and a support structure 3. The support structure 3 is disposed between the surface layer structure 1 and the bottom layer structure 2, and the support structure 3 includes a plurality of first multi-filament yarns 31, each of the first multi-filament yarns 31 connecting the surface layer structure 1 and the bottom layer structure 2, and interlacing the support structure 3.

Preferably, the denier of the surface layer structure 1 and the bottom layer structure 2 is between 10 to 150 D. The surface layer structure and the bottom layer structure each includes a non-elastic fiber and an elastic fiber; in which the ratio of the non-elastic fiber to the elastic fiber is between 70:30 and 97:3, further is between 85:15 and 97:3. Further, the non-elastic fiber is at least one selected from the group consisting of nylon, polyester fiber, polylactic acid fiber, polytrimethylene terephthalate fiber, and cellulose fiber, and the elastic fiber is at least one selected from Spandex®, Lycra®, natural rubber and synthetic rubber.

Preferably, the thickness of the support structure is between 0.85 mm and 5 mm, further is between 2 mm and 5 mm More specifically, as shown in the sectional view of FIG. 1, the first multi-filament yarn 31 crosses to form an S-shaped structure, such that the multi-filament three-dimensional knitted fabric F has better support force, proper elasticity, and cushioning.

Referring to FIG. 2A to FIG. 2B, which is a partial enlarged view of the first multi-filament yarn 31 of FIG. 1, compared with the mono-filament yarn made by ordinary single-hole spinneret, the first multi-filament yarn is twisted from 2 to 75 yarns, further from 2 to 10 yarns. For example, as shown in FIG. 2A, the first multi-filament yarn 31 is a multifilament yarn formed by twisting together a first yarn 312 and a second yarn 314. As shown in FIG. 2B, a third yarn 316 is further included. The first multi-filament yarn can be manufactured by a conventional melt spinning device. A multi-filament yarn composed of a plurality of monofilament fibers provides better support and elasticity, has a higher bendability, and is softer than mono-filament yarns having the same diameter.

In detail, a single filament of a multifilament yarn is generally thinner than an ordinary monofilament yarn. Further, the denier of the first multi-filament yarn is between 5 and 60 D, further is between 10 and 60 D, and the first multi-filament yarn is twisted from 2 to 75 yarns, and the denier of the yarn is between 0.5 to 30 D. In addition, the shrinkage of the multi-filament three-dimensional knitted fabric is between −5 and 0%.

In more detail, the first yarn 312 is a non-elastic yarn and is at least one selected from the group consisting of nylon, polyester fiber, polylactic acid fiber, polytrimethylene terephthalate fiber, and cellulose fiber.

Next, the present disclosure further provides a system S of manufacturing a multi-filament three-dimensional knitted fabric F. Specifically, the manufacturing system S is a so-called weaving device. The weaving device has the conventional structure of a commercial loom, but has improved structure and operating parameters. Generally, the weaving device includes basic components such as a control mechanism, a conveying mechanism, a yarn feeding mechanism, a yarn storage unit, a yarn feeding unit, a weaving unit, and a cloth winding mechanism, and the functions of each component are common knowledge in the field, and will not be reiterated herein.

In the process of weaving, the yarn feeding mechanism drives the yarn storage unit to feed the yarn into the yarn feeding unit, and the yarn feeding unit feeds the yarn into the weaving unit by providing a fixed inlet angle. The weaving unit includes a syringe and a knitting needle. The knitting needle is inserted into a groove on the surface of the syringe, and the knitting process is controlled by various cams in a cam box to form a yarn loop. Among the basic components of the weaving device 41, the operating parameters in the yarn feeding unit are particularly adjusted in the present disclosure.

Specifically, the knitting needles of the weaving unit are thinner than ordinary knitting needles, and has a thickness of 32 purls and 32 knits (1 purl/knit=0.001 cm=10 microns), so that the multi-filament three-dimensional knitted fabric manufactured by the weaving unit is more delicate and has better covering characteristics. In other words, the thickness of 32 purls or knits means that the thickness of the knitting needle is 0.032 cm, and the thinner the knitting needle is, the higher the precision the product provides. Furthermore, the present disclosure adjusts the amount of yarn that is fed, and adjusts the bind-off points of the purls, knits, and half stitches. The length of a loop of yarn fed by the weaving device for a purl or a knit is between 450 and 700 cm, the length of a loop of yarn fed by the weaving device for a half stitch is between 1100 and 1800 cm, and a bind-off point of the purl has a scale ranging between 5 and 10, the bind-off point of the knit has a scale ranging between 5 and 10, and the bind-off point of the half stitch has a scale between 0 and 5.

In addition, reference is made to FIG. 3, which is a structure schematic view of the yarn feeder nozzle 5 of the yarn feeding unit in the system of manufacturing a multi-filament three-dimensional knitted fabric. Specifically, the yarn feeder nozzle 5 includes a base 51 and a yarn pulling member 52. The yarn pulling nozzle 52 is disposed at a lower portion of the base 51. The base 51 is in the shape of a bar, and further includes a bar-shaped hole 511 on the upper part and a screw hole 512 on the mid-lower part. Specifically, the bar-shaped hole 511 and the screw hole 512 are used for adjusting installation positions. The yarn pulling member 52 includes a yarn inlet 521, the yarn Y passes through the yarn inlet 521 at a yarn inlet angle θ1 between 40 and 55 degrees. The yarn inlet angle θ1 of the yarn inlet 521 refers to an included angle between the yarn Y1 and a horizontal plane (indicated by a dotted line) when the yarn Y1 passes through the yarn inlet 521. The yarn pulling member 52 is in the shape of a block, and has a first side 522 and a second side 523 opposite to each other, the first side 522 being an inclined surface, and the second side 523 including a convex surface away from the first side. In addition, the yarn pulling member 52 further includes a connecting portion (not shown in the figure) fixed to one side of the base 51.

By the structural design of yarn feeder nozzle 5, the yarn entry angle θ1 can be modified, and the quality of the multi-filament three-dimensional knitted fabric F can be improved. By taking into account both elastic recovery rate and hand feel, and providing better support and stiffness, the rebound hardness of the multi-filament three-dimensional knitted fabric F can reach more than 90 degrees.

Therefore, through the technical features of “the support structure includes a plurality of first multi-filament yarns” and “and each of the first multi-filament yarns is connected to the surface layer structure and the bottom layer structure, and interlacingly form the support structure, and interlacing the support structure”, the multi-filament three-dimensional knitted fabric of the present disclosure has a proper supporting force that is on par with that of fabric with monofilament fibers, as well as the effects of a better and more long-lasting elasticity property, and further provides better skin-friendly tactility and comfort, which overcomes the problems of itching and swelling of the skin from yarn puncturing out of the fabric surface.

Furthermore, the multi-filament three-dimensional knitted fabric of the present disclosure effectively improves on ordinary monofilament yarns. The technical features of “the first multi-filament yarn is twisted from 2 to 75 yarns” of the present disclosure provides the fabric with a better support and more elasticity. Therefore, the multi-filament three-dimensional knitted fabric of the present disclosure has a higher bendability, and is softer than mono-filament yarns with the same diameter, which further overcomes the problem of the monofilament fibers protruding from the surface layer.

Results from subjecting the multi-filament three-dimensional knitted fabric of the present disclosure to evaluation by the KES Kawabata fabric feel analysis evaluation system are provided herein. The multi-filament three-dimensional knitted fabric of the present disclosure has a fabric compression recovery rate of ≥90%, and a fabric smoothness friction coefficient of ≤0.35.

In addition, the present disclosure further improves the manufacturing system and manufacturing method of the multi-filament three-dimensional knitted fabric, overcomes issues relating to thickness loss and defects of creases or crushing during a conventional manufacturing process, and further improves the efficiency and reduces the cost of the manufacturing process.

The foregoing description of the exemplary embodiments of the disclosure has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching.

The embodiments were chosen and described in order to explain the principles of the disclosure and their practical application so as to enable others skilled in the art to utilize the disclosure and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the present disclosure pertains without departing from its spirit and scope. 

What is claimed is:
 1. A multi-filament three-dimensional knitted fabric, comprising: a surface layer structure; a bottom layer structure; and a support structure disposed between the surface layer structure and the bottom layer structure; wherein the support structure includes a plurality of first multi-filament yarns, and each of the first multi-filament yarns is connected to the surface layer structure and the bottom layer structure, and interlacingly form the support structure.
 2. The multi-filament three-dimensional knitted fabric according to claim 1, wherein each of the surface layer structure and the bottom layer structure includes a non-elastic fiber and an elastic fiber; wherein the ratio of the non-elastic fiber to the elastic fiber is between 70:30 and 97:3.
 3. The multi-filament three-dimensional knitted fabric according to claim 1, wherein a thickness of the support structure is between 0.85 mm and 5 mm.
 4. The multi-filament three-dimensional knitted fabric according to claim 1, wherein a shrinkage of the multi-filament three-dimensional knitted fabric is between −5 and 0%.
 5. The multi-filament three-dimensional knitted fabric according to claim 1, wherein, a denier of the first multi-filament yarn is between 5 and 60 D.
 6. The multi-filament three-dimensional knitted fabric according to claim 1, wherein, the first multi-filament yarn is twisted from 2 to 75 yarns, and the denier of the yarn is between 0.5 to 30 D.
 7. The multi-filament three-dimensional knitted fabric according to claim 6, wherein the yarn is at least one selected from the group consisting of nylon, polyester fiber, polylactic acid fiber, polytrimethylene terephthalate fiber, and cellulose fiber.
 8. A system of manufacturing a multi-filament three-dimensional knitted fabric, comprising: a weaving device including a yarn feeding unit, and the yarn feeding unit has a yarn feeder nozzle for interlacing and weaving at least one multifilament yarn into the multi-filament three-dimensional knitted fabric; wherein the multi-filament yarn passes through a yarn inlet of the yarn feeder nozzle at a yarn inlet angle between 40 and 55 degrees; wherein the multi-filament three-dimensional knitted fabric includes: a surface layer structure; a bottom layer structure; and a support structure disposed between the surface layer structure and the bottom layer structure; wherein the support structure includes a plurality of first multi-filament yarns, and each of the first multi-filament yarns is connected to the surface layer structure and the bottom layer structure, and interlacingly form the support structure.
 9. A method of manufacturing a multi-filament three-dimensional knitted fabric, comprising: weaving at least one multifilament yarn into a weaving device to form the multi-filament three-dimensional knitted fabric; the multi-filament three-dimensional knitted fabric including: a surface layer structure; a bottom layer structure; and a support structure disposed between the surface layer structure and the bottom layer structure; wherein the support structure includes a plurality of first multi-filament yarns, and each of the first multi-filament yarns is connected to the surface layer structure and the bottom layer structure, and interlacingly form the support structure; wherein the weaving device includes a yarn feeding unit, and the yarn feeding unit has a yarn feeder nozzle for interlacing and weaving at least one multifilament yarn into the multi-filament three-dimensional knitted fabric; wherein the multi-filament yarn passes through a yarn inlet of the yarn feeder nozzle at a yarn inlet angle between 40 and 55 degrees.
 10. The method according to claim 9, wherein, in the step of weaving at least one multifilament yarn into a weaving device to form the multi-filament three-dimensional knitted fabric, the length of a loop of yarn fed by the weaving device for a purl or a knit is between 450 and 700 cm, the length of a loop of yarn fed by the weaving device for a half stitch is between 1100 and 1800 cm, and a bind-off point of the purl has a scale ranging between 5 and 10, the bind-off point of the knit has a scale ranging between 5 and 10, and the bind-off point of the half stitch has a scale between 0 and
 5. 